Surgical instrument with pressure distribution device

ABSTRACT

The present disclosure is directed to a surgical apparatus, comprising an anvil jaw configured to form at least one surgical staple, a cartridge jaw configured to deploy one or more surgical staples against the anvil jaw, and a pressure distribution device attached to at least one of the anvil jaw and the cartridge jaw, wherein the pressure distribution device is configured to distribute a clamping pressure to a target tissue during a clamping and a stapling of the target tissue.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming the benefit of and priority to U.S. patent application Ser. No. 15/367,260, filed Dec. 2, 2016, which is a divisional application claiming the benefit of and priority to U.S. patent application Ser. No. 13/713,260, filed Dec. 13, 2012, now U.S. Pat. No. 9,522,002, the entire disclosures of each of which being incorporated by reference herein.

BACKGROUND 1. Technical Field

The present disclosure relates to medical instruments and the use thereof. More particularly, the present disclosure is directed to medical staplers and pressure distribution during a clamping and/or stapling procedure.

2. Background of Related Art

Generally, surgical fastener applying instruments grasp or clamp tissue between opposing jaw structures and join the tissue by means of surgical fasteners. In some such instruments, a knife is provided to cut the tissue which has been joined by the fasteners. The fasteners are typically in the form of surgical staples, although other surgical fasteners may also be utilized, such as, for example, clips or two part polymeric surgical fasteners.

Certain surgical fastener applying instruments include two elongated jaw members which are used to capture or clamp tissue therebetween. Typically, one of the jaw members carries a cartridge assembly which houses a plurality of staples arranged in at least two lateral rows, while the other jaw member includes an anvil which defines a surface for forming the staple legs as the staples are driven from the cartridge assembly. Where two part fasteners are used, the jaw member which includes the anvil carries a mating part of the two part fastener, e.g. the receiver. Generally, the staple formation process is affected by the interaction between one or more longitudinally moving camming members and a series of individual staple pushers. As the camming members travel longitudinally through the cartridge carrying jaw member, the individual staple pushers are urged upwardly into a backspan of the staples supported within the cartridge assembly to sequentially eject the staples from the cartridge assembly. A knife may be provided to travel with the camming members between the staple rows to cut the tissue between the rows of formed staples.

Pinching may occur at the site of clamped tissue along the periphery of the jaw members due to a very localized high pressure gradient between the clamped tissue and the tissue lying outside the jaws. This pinching may affect the quality of the procedure. Solutions to these issues are described hereinbelow.

SUMMARY

In accordance with at least one aspect of the present disclosure, a surgical apparatus includes an anvil jaw configured to form at least one surgical staple, a cartridge jaw configured to deploy one or more surgical staples against the anvil jaw, and a pressure distribution device attached to at least one of the anvil jaw and the cartridge jaw, wherein the pressure distribution device is configured to distribute a clamping pressure to a target tissue during a clamping and a stapling of the target tissue.

Each pressure distribution device may include at least one flap extending from a side of a respective anvil jaw and cartridge jaw.

Each pressure distribution device may be made of a shape memory material, or can be reinforced with a shape memory material.

Each pressure distribution device may be furled up in a retracted state against at least one of the anvil jaw and the cartridge jaw such that the apparatus has a low profile.

Each of the anvil jaw and the cartridge jaw may comprise at least one pressure distribution device attached to a surface thereof.

Each pressure distribution device may be furled up in a retracted state such that the apparatus has a low profile.

Each pressure distribution device may be substantially U-shaped and extends beyond a distal end of the respective anvil jaw and cartridge jaw.

At least one pressure distribution device may include an inflatable bladder that is deflated in a retracted state and inflated in an extended state.

At least one pressure distribution device may further include a deployment member that holds the at least one flap in a retracted state, and is configured to allow the at least one flap to move to an extended state.

The deployment member may be a tubular member slidably disposed on the apparatus, configured to slide between a distal position surrounding the at least one flap and holding the at least one flap in the retracted state, and a proximal position to release the at least one flap and allow the at least one flap to move to an extended state.

The deployment member may include at least one or more ties that bind the at least one flap in the retracted state.

In accordance with still yet another aspect of the present disclosure, a method includes providing a surgical apparatus including an anvil jaw, a cartridge jaw configured to deploy one or more surgical staples into the anvil jaw, and a pressure distribution device attached to at least one of the anvil jaw and the cartridge jaw, wherein the pressure distribution device is configured to distribute pressure to a target tissue during clamping and stapling of a target tissue, and deploying the pressure distribution device before clamping and stapling a target tissue.

The deploying of the pressure distribution device may be performed after clamping but before stapling.

Each pressure distribution device may be furled up in a retracted state against at least one of the anvil jaw and the cartridge jaw such that the apparatus has a low profile, the method further comprising passing the surgical apparatus through a cannula in the retracted state.

The method may further include the step of unfurling the pressure distribution device from the retracted state to a deployed state after passing the pressure distribution device through a cannula.

The method may further include the step of clamping target tissue after unfurling the pressure distribution device.

The method may further include the step of stapling target tissue after clamping target tissue.

The method may further include the step of unclamping target tissue after stapling.

The method may further include the step of furling the pressure distribution device back into the retracted state after unclamping target tissue.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other aspects, features, and advantages of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of at least one embodiment of a surgical instrument in accordance with the present disclosure;

FIG. 2 is a front, elevational view, partially in section, of the surgical instrument of FIG. 1;

FIG. 3 is a perspective view of the surgical instrument of FIG. 1;

FIG. 4 is a schematic, perspective view of another embodiment of a surgical instrument in accordance with the present disclosure;

FIG. 5A is a front, elevational view, partially in section, of at least one embodiment of a surgical instrument in accordance with the present disclosure, shown in a retracted state;

FIG. 5B is a front, elevational view, partially in section, of the surgical instrument of FIG. 5A, shown in an extended or deployed state;

FIG. 6A is a front, elevational view, partially in section, of another embodiment of a surgical instrument in accordance with the present disclosure, shown in a retracted state;

FIG. 6B is a perspective view of the surgical instrument of FIG. 6A, shown in a retracted state;

FIG. 6C is a perspective view of the surgical instrument of FIG. 6A, shown in a deployed or extended state;

FIG. 7A is a front, elevational view, partially in section, of another embodiment of a surgical instrument in accordance with the present disclosure, shown in a retracted state;

FIG. 7B is a front, elevational view, partially in section, of the surgical instrument of FIG. 7A, shown in a deployed or extended state;

FIG. 8A is a front, elevational view of another embodiment of a surgical instrument in accordance with the present disclosure, shown in a retracted state;

FIG. 8B is a front, elevational view, partially in section, of the surgical instrument of FIG. 8A, shown in a deployed or inflated state;

FIG. 9A is a front, elevational view, partially in section, of another embodiment of a surgical instrument in accordance with the present disclosure, shown in a retracted state; and

FIG. 9B is a front, elevational view, partially in section, of the surgical instrument of FIG. 9A, shown in a deployed or extended state.

DETAILED DESCRIPTION

Like reference numerals may refer to similar or identical elements throughout the description of the figures. As shown in the drawings and described throughout the following description, as is traditional when referring to relative positioning on a surgical instrument, the term “proximal” refers to the end of the apparatus that is closer to the user and the term “distal” refers to the end of the apparatus that is farther away from the user. The term “clinician” refers to any medical professional (e.g., doctor, surgeon, nurse, or the like) performing a medical procedure involving the use of embodiments described herein.

Particular embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, the disclosed embodiments are merely examples of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure.

In accordance with at least one aspect of the present disclosure, a surgical instrument is described herein. The surgical instrument may be a tissue stapling apparatus or a tissue clamping apparatus, such as, for example, an end effector, disposable loading unit (DLU), single use loading unit (SULU), multi use loading unit (MULU), etc. The apparatus can include removable and replaceable parts, such as a reload or loading unit that includes the anvil and cartridge assembly (SULU). The cartridge assembly may be removable and replaceable in an instrument that has jaws that are intended to be reused during the same procedure, or removable and replaceable in a SULU.

A tissue stapling apparatus, as shown in FIGS. 1-9B, may generally include an anvil jaw supporting an anvil and a cartridge jaw supporting a cartridge assembly, wherein the anvil and cartridge assembly cooperate with one another to clamp the target tissue, and to deploy one or more surgical staples into target tissue and form the one or more surgical staples.

Each embodiment shown in the figures further includes at least one embodiment of a pressure distribution device or attachment in accordance with the present disclosure. Generally, the at least one pressure distribution device or attachment may be permanently or selectively attached to one or both of the anvil jaw and the cartridge jaw.

The pressure distribution device or attachment may be made into any suitable shape to contact a target tissue and reduce the pressure associated with a clamping of the target tissue by the surgical instrument. Specific embodiments of the pressure distribution device or attachment are described in more detail below.

The apparatus can include a manually operated and manually powered handle portion, a motorized powered handle portion with an internal or external power source, or other interface for actuating the end effector.

Referring specifically to FIGS. 1-3, an end effector 100, in accordance with an embodiment of the present disclosure, for use with a surgical instrument is shown. End effector 100 includes an anvil jaw or portion 102, a cartridge jaw or portion 104, and a pressure distribution device or attachment 110 is shown. Reference may be made to U.S. Patent Publication No. 2009/0314821, filed on Aug. 31, 2009, the entire content of which is incorporated herein, for a detailed discussion of the construction and operation of an exemplary surgical instrument.

As depicted, the end effector 100 is clamped down on the target tissue “T” with the pressure distribution device or attachment 110 shown in an extended or deployed state. The pressure distribution device or attachment 110 is configured to distribute a clamping pressure to the target tissue “T” during clamping and stapling of the target tissue “T”.

The pressure distribution device or attachment 110 includes at least one anvil flap 112 and/or at least one cartridge flap 114 extending from a side of the anvil jaw 102 or the cartridge jaw 104, respectively.

As shown in FIGS. 1-3, the flaps 112, 114 may be substantially U-shaped in an axial direction such that the flaps 112, 114 extend from a proximal portion and wrap around a distal end of respective anvil jaw 102 and cartridge jaw 104.

In operation, when anvil jaw 102 and cartridge jaw 104 are clamped onto target tissue “T”, flaps 112, 114 of pressure distribution device or attachment 110 extend outwardly therefrom and across the target tissue “T”. In so doing, flaps 112, 114 increase a surface area of the tissue contacting surfaces of anvil jaw 102 and cartridge jaw 104. By increasing the surface area of the tissue contacting surfaces of anvil jaw 102 and cartridge jaw 104, pressure distribution device 110 distributes a clamping load away from the hard edges of anvil jaw 102 and cartridge jaw 104, wherein the clamping load gradually transitions.

Flaps 112, 114 may be sized to any desired width or length on jaws 102 and 104. Flaps 112, 114 do not have to be of identical size or shape. For example, flap 112 may be wider, thicker, and/or longer than flap 114 and vice versa.

Each flap 112, 114 of pressure distribution device or attachment 110 may be made of a high durometer rubber, shape memory material, a foam, a gel, a plastic, a spring loaded plastic, or any other suitable material.

Referring to FIG. 4, another embodiment of an end effector 300 including a pressure distribution device or attachment 310 is shown. The pressure distribution device or attachment 310 includes a first anvil flap 312 a and a second anvil flap 312 b attached to opposed lateral sides of the anvil jaw 302. Pressure distribution device or attachment 310 also includes a first cartridge flap 314 a and a second cartridge flap 314 b attached to opposed lateral sides of the cartridge jaw 304.

With reference to FIGS. 5A and 5B, an end effector 300′ is shown illustrating an embodiment of pressure distribution device or attachment 310′ in a retracted state and an extended or deployed state, respectively. As shown in FIG. 5A, the flaps 312′, 314′ may be furled up against the anvil jaw 302′ and the cartridge jaw 304′, respectively, such that the transverse cross-sectional profile of the end effector 300′, has a low profile, wherein the end effector 300′ is capable of being inserted through a cannula (not shown) to reach a target surgical site. In FIG. 5B, the flaps 312′, 314′ are unfurled such that the flaps 312′, 314′ extend laterally outward from the anvil jaw 302′ and the cartridge jaw 304′, respectively, to increase the effective surface area of each jaw, as described above. The flaps may be temporarily attached to the jaws initially. Yes, they can be temporarily attached by means or adhesive or snap features.

Referring now to FIGS. 6A-6C, a deployment device/tube 120 may be provided for use in conjunction with an end effector 300″ and pressure distribution device or attachment 310″. Deployment tube 120 may be a tubular member slidably connected to or disposed about end effector 300″ such that the deployment tube 120 may selectively cover and expose the flaps 312″, 314″ of the anvil jaw 302″ and the cartridge jaw 304″, respectively.

As seen in FIGS. 6A and 6B, pressure distribution device or attachment 310″ is shown in a retracted state having the deployment tube 120 disposed over the flaps 312″, 314″, whereby deployment tube 120 facilitates passage of end effector 300″ through a cannula (not shown). FIG. 6C shows the deployment tube 120 in a withdrawn or retracted condition exposing the flaps 312″, 314″ such that the flaps 312″, 314″ are free to unfurl into the extended or deployed state, either manually or due to restoring force acting on the flaps 312″, 314″. The tube could be integral to the instrument working shaft. The tube may also take the form of a cap that is pulled off manually by using a set of graspers after having been inserted through the cannula.

Referring now to FIGS. 7A and 7B, a pressure distribution device or attachment 410 in accordance with another embodiment of the disclosure, associated with end effector 400, is shown in a retracted state and an extended or deployed state, respectively. As shown in FIG. 7A, the flaps 412, 414 may be furled or folded to overlie the tissue contacting surfaces and are sandwiched between anvil jaw 402 and the cartridge jaw 404 such that the end effector 400 is capable of being inserted through a cannula (not shown) to reach a surgical site. In FIG. 7B, the flaps 412, 414 are unfurled after separating the anvil jaw 402 and the cartridge jaw 404 such that the flaps 412, 414 extend laterally outward from the anvil jaw 402 and the cartridge jaw 404 to increase the effective surface area of each jaw.

It is important to note that while the flaps 412, 414 are shown as rigid linkages attached to the anvil jaw 402 and cartridge jaw 404 via a mechanical hinge, flaps 412, 414 may be of any suitable material and attached as described herein or otherwise.

Referring now to FIGS. 8A and 8B, a pressure distribution device or attachment 510 in accordance with another embodiment of the present disclosure, associated with end effector 500, is shown in a retracted state and an extended or deployed state, respectively. Pressure distribution device or attachment 510 includes at least one inflatable bladder 516 disposed in at least one flap 512, 514 that is deflated in a retracted state and inflated in an extended or deployed state. The inflatable bladders 516 may be connected to a pressurized fluid supply (not shown) and inflated/deflated as need or desired. The flaps may be made from an elastic membrane so that they extend and retract. They can be made of a plastic or elastomeric material to provide flexibility. The deflection of the flaps would be controlled in the design by means of thickness. Closer to the jaws, the flaps would be thicker to minimize the amount of deflection in the flap. The flaps would progressively get thinner further away from the jaws to allow for more deflection.

As shown in FIG. 8A, the flaps 512, 514 may be deflated and retracted up against the anvil jaw 502 and the cartridge jaw 504, respectively, such that the profile of the end effector 500 allows insertion through a cannula (not shown) to reach a surgical site. In FIG. 8B, the bladders 516 are pressurized with fluid (e.g., air, CO2, saline, etc.) and flaps 512, 514 are inflated such that the flaps 512, 514 extend laterally outward from the anvil jaw 502 and the cartridge jaw 504, respectively, to increase the effective surface area of each jaw. Flaps 512, 514 may also be deflated for removal or withdrawal of the end effector 500 through the cannula (not shown). In any of the embodiments disclosed herein, the pressure distribution device or attachment can include one or more inflatable and/or Tillable flap extending away from the jaw or jaws in one or more directions.

Referring now to FIGS. 9A and 9B, an end effector 400′ is shown illustrating a pressure distribution device or attachment 410′ in a retracted state and an extended or deployed state, respectively. Pressure distribution device or attachment 410′ includes at least one deployment member 118, according to an embodiment of the present disclosure that holds the flaps 412′, 414′ in the retracted state. For example, deployment members 118 may be one or more ties or tethers that bind the flaps 412′, 414′ to the retracted state. Other means for temporarily retaining the flaps are adhesives, snap features, ties, straps, etc.

The deployment members 118 are configured to selectively separate from flaps 412′, 414′ to allow the flaps 412′, 414′ to unfurl to the extended or deployed state. For example, deployment members 118 may be manually cut, snapped, or untied. In other embodiments, the deployment members 118 may be made of a dissolvable material such that the introduction of a fluid (e.g., saline or water) will dissolve the deployment members 118 and allow the flaps 412′, 414′ to unfurl to the extended or deployed state.

As shown in FIG. 9A, the flaps 412′, 414′ may be folded or furled up against the anvil jaw 402′ and the cartridge jaw 404′ such that the profile of the end effector 400′ allows insertion through a cannula (not shown) to reach a target surgical site. In FIG. 9B, the deployment members 118 are snapped, and flaps 412′, 414′ are unfurled such that the flaps 412′, 414′ extend laterally outward from the anvil jaw 402′ and the cartridge jaw 404′ to increase the effective surface area of each jaw. As with other embodiments, flaps 412′, 414′ may be furled or folded back into a retracted state for removal of the end effector 400′ through the cannula (not shown). The flaps, in any of the embodiments disclosed herein, can extend in one or more directions, from one or more sides of the jaw or jaws.

It is important to note that while the flaps 412′, 414′ are shown as rigid linkages attached to the anvil jaw 402′ and the cartridge jaw 404′ via a mechanical hinge, flaps 412′, 414′ may be of any suitable material and attached as described herein or otherwise.

In at least some embodiments, the above described pressure distribution devices or attachments may be combined in any suitable manner. For example, a pressure distribution device or attachment may include at least one of a flap having an inflatable bladder, a flap having a tie that binds the flap into the retracted position, and a tubular member that prevents the flap from moving to the extended or deployed position. Many other combinations are contemplated, but are not expressly disclosed herein for the sake of brevity.

In at least one aspect of the present disclosure, a method includes providing a surgical instrument and/or end effector having a pressure distribution device or attachment as described herein, and deploying the pressure distribution device or attachment before clamping and stapling a target tissue.

Sensors may be used, in any of the embodiments disclosed herein. A pressure sensor can be incorporated in or on the pressure distribution device. An inflatable device can include a sensor for the pressure of the fluid or other medium inside the pressure distribution device. The flaps may be constructed of or include thin film sensors (strain gauges, capacitive sensors, etc.) that will provide feedback to the handle and ultimately the user with regards to tissue thickness and the pressure being applied to the tissue by the flaps. This electrical data may be communicated to the handle by means of a hardwired connection as well as a wireless data communication.

It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances. The embodiments described with reference to the attached drawing figures are presented only to demonstrate certain examples of the disclosure. Other elements, steps, methods and techniques that are insubstantially different from those described above and/or in the appended claims are also intended to be within the scope of the disclosure. 

1-19. (canceled)
 20. A surgical apparatus, comprising: a first jaw; a second jaw; and a pressure distribution device including at least one flap attached to the first or second jaw, the at least one flap extending laterally from at least one side of the first or second jaw and distally beyond a distal end of the first or second jaw.
 21. The surgical apparatus according to claim 20, wherein the first jaw is an anvil jaw configured to form at least one surgical staple, and the second jaw is a cartridge jaw configured to deploy one or more surgical staples against the anvil jaw.
 22. The surgical apparatus according to claim 20, wherein the at least one flap is substantially U-shaped and extends laterally from opposed sides of the first or second jaw and wraps around the distal end of the first or second jaw.
 23. The surgical apparatus according to claim 20, wherein the at least one flap has a tissue facing surface that increases a surface area of a tissue facing surface of the first or second jaw.
 24. The surgical apparatus according to claim 23, wherein the tissue facing surface of the at least one flap curves upwardly from an inner edge disposed adjacent to the first or second jaw to an outer edge of the at least one flap.
 25. The surgical apparatus according to claim 24, wherein the at least one flap has an outwardly facing surface that is substantially planar.
 26. The surgical apparatus according to claim 24, wherein the at least one flap decreases in thickness from the inner edge to the outer edge.
 27. The surgical apparatus according to claim 20, wherein the at least one flap includes a first flap extending from the first jaw and a second flap extending from the second jaw.
 28. The surgical apparatus according to claim 20, wherein the at least one flap is formed from a high durometer rubber, a shape memory material, a foam, a gel, a plastic, or a spring loaded plastic.
 29. A surgical apparatus, comprising: a first jaw including a tissue facing surface; a second jaw including a tissue facing surface; and a first flap coupled to the first jaw, the first flap extending laterally from at least one side of the first jaw and distally beyond a distal end of the first jaw to increase a surface area of the tissue facing surface of the first jaw.
 30. The surgical apparatus according to claim 29, wherein the first flap is substantially U-shaped and extends laterally from opposed sides of the first jaw and wraps around the distal end of the first jaw.
 31. The surgical apparatus according to claim 29, wherein the tissue facing surfaces of the first and second jaws are planar, and a tissue facing surface of the flap is non-planar.
 32. The surgical apparatus according to claim 29, further comprising a second flap coupled to the second jaw.
 33. The surgical apparatus according to claim 32, wherein the first and second flaps are of identical size and shape.
 34. A method of performing a surgical procedure comprising: clamping tissue between first and second jaws of a surgical apparatus such that at least one flap of a pressure distribution device that is attached to the first or second jaw and extends laterally from at least one side of the first or second jaw and distally beyond a distal end of the first or second jaw increases a surface area of a tissue contacting surface of the first or second jaw.
 35. The method according to claim 29, wherein the at least one flap includes a first flap extending from the first jaw and a second flap extending from the second jaw such that clamping of the tissue distributes a clamping load away from hard edges of the first and second jaws. 